Installation Box Channel Layout for Foam-Secure Wall Fixing

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Solution Overview

Problem

Existing flush-mounted installation boxes can be pushed out of the wall opening during the expansion of highly expanding assembly foams, making it difficult to securely fix the box using conventional methods.

Innovation Solution

The installation box features a channel on the side facing away from the installation space, with inlet and lateral outlet openings, allowing assembly foam to be directed laterally and prevent excessive foam from reaching the rear of the box, thus ensuring secure fixation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If highly expanding assembly foam is used to fix the installation box, then the installation speed and ease of operation are improved, but the installation box may be pushed out of the wall opening due to excessive foam expansion

Engineering Contradiction:
Improveease of installationVSAvoidsecure fixation
Core Design Contradiction:
Ease of operationVSReliability

Solution Approach 1:

The base is segmented into a foam receiving area and a foam exclusion area by the raised ridge. This segmentation directs the expanding foam into specific zones (side walls and rear surface) while preventing it from accumulating behind the base, thus resolving the contradiction between using highly expanding foam for easy installation and preventing the box from being pushed out.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The raised ridge acts as an intermediary structure between the foam application and the rear surface of the base. It mediates the foam expansion process by providing a physical barrier that redirects foam flow laterally toward the side walls, preventing direct backward expansion that would push the box out while still allowing sufficient foam for secure fixation.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Reliability

If less expanding foam is used to prevent the installation box from being pushed out, then the risk of displacement is reduced, but the fixation strength and reliability are weakened

Engineering Contradiction:
Improvesecure fixationVSAvoidfixation strength
Core Design Contradiction:
ReliabilityVSStrength

Solution Approach 1:

The base structure segments the foam distribution into multiple zones: lateral zones along the side walls and a restricted zone at the rear. This segmentation allows the foam to provide strong fixation at the critical lateral interfaces without requiring excessive foam volume that would cause backward displacement, thus maintaining fixation strength while preventing displacement.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The raised ridge introduces a vertical dimension to the foam containment strategy. By creating a lateral barrier at a certain height, it redirects the foam expansion from a purely radial pattern to a controlled lateral flow, enabling effective fixation through side wall bonding without the need for excessive foam quantity.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

3Device complexity

If conventional foam application methods are used, then the installation process is simple, but the foam cannot be precisely directed to avoid pushing the installation box out

Engineering Contradiction:
Improveinstallation process complexityVSAvoidfoam placement precision
Core Design Contradiction:
Device complexityVSManufacturing precision

Solution Approach 1:

The raised ridge structure is pre-formed on the base during manufacturing, creating a built-in foam directing system. This preliminary action eliminates the need for complex external foam directing devices or complex application techniques, as the structure itself guides the foam flow laterally while maintaining simple installation procedures.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The base structure serves itself by incorporating the foam directing function directly into its geometry. The raised ridge automatically directs the expanding foam without requiring external tools, complex application procedures, or additional components, thus achieving precise foam placement with simple installation processes.

Inventive Principle:
Principle #25Self-service

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This design allows for secure and flexible installation of the box using highly expanding assembly foams without risking the box being pushed out of the wall opening, enabling quick and precise installation without additional tools.

Implementation Method 1

One characteristic of polyurethane foam is that it swells considerably during curing, usually increasing in volume by a factor of 20 to 30.

Methodology Applied
Scientific EffectExpansion:

Implementation Method 2

assembly foam can be sprayed in a conventional manner by means of a lance through the inlet opening, which is arranged, for example, in the floor of the installation box, behind the box, i.e. onto the rear side of the floor facing away from the installation space, but is then directed laterally through the channel

Methodology Applied
Scientific EffectFlow:

Implementation Method 3

This has the advantage that expansion foam spreads rapidly from the application site and can flow into cavities and undercuts before it hardens

Methodology Applied
Scientific EffectAdhesion: Adhesive

Data Source

PatentEP4560858A1Installation box for electrical installation
Publication Date: 2025.05.28 F TRONIC WINFRIED FOHS BESCHRAENKTER HAFTUNG
  • EP4560858A1 patent drawingFigure 1~2
  • EP4560858A1 patent drawingFigure 3~4
  • EP4560858A1 patent drawingFigure 5~6

AI summary

The invention relates to an installation box for electrical installations, comprising a pot-shaped box body which is open on one side and has at least one side wall (3) and a base (2) adjoining thereto in a transition region, which enclose an installation space (4), wherein a plurality of breakable and/or pierceable installation openings (5) are provided in the box body, characterized in that a channel (11) is provided on the rear side of the base (2) facing away from the installation space (4), into which channel at least one inlet opening (9) from the installation space (4) opens, and in that the channel (11) has at least one lateral outlet opening (12) which is positioned near the transition region.